Method of manufacturing components with cavities by explosive welding of metal blanks

ABSTRACT

A method of manufacturing multilayer components with inner hollows by the explosive welding of metal blanks, one of the blanks being provided with depressions filled with fusible or soluble materials which are removed after welding.

ite States Derihas et a1. May 29, 1973 METHOD OF MANUFACTURING [58]Field of Search ..29/470.1, 486, 421 E, COMPONENTS WITH CAVITIES BY29/470.9, 423, 497.5, 481, 557 EXPLOSIVE WELDING OF METAL [56]References Cited BLANKS [76] Inventors: Andrei Andreevich Deribas,ulitsa UNITED STATES PATENTS f f" Novoslbfrski 2,982,012 5/1961 Wilkinset al ..29/470.9 x Mkhallmlch 2 986 810 6/1961 BriCk. ..29/423 "litsaFilatova, 1/22, 51, Kiev; 3:044:160 7 1962 Jaffee .29/423 Felix IoviclhM ve nk ulitsa 3,106,014 10 1963 Brick et al. 29 4709 Pravdy, l, kv. 24,Novosibirsk; 3,135,044 6/1964 Mote, Jr. et a1, ..29/423 Vladimir lvan v01, 1,, 3,201,858 8/1965 v61 i 29/423 ux seinaya ulitsa, 8, kv. 4, Kiev;Valery 3 0 1zawa.... fl g 'rl'g z s' ig g lg if 3,543,388 12/1970 Blanket al. ..29/486 i i 3,264,731 8/1966 Chudzik ..29/486 GerasimovichOstapenko, deceased, late of Kiev; Klara Mikhailovna Ivanova,administrator, bulvar Lesi ukrainki, 2, kv. 20, Kiev; Alexei NikolaevichOstapenko, administrator, ulitsa Molodezhnaya, 4, kv. 220, Moscow, allof USSR.

Filed: Jan. 29, 1970 Appl. No.: 6,797

11.8. C1. ..29/470.]l, 29/423, 29/481 lint. Cl. ..B23k 21/00 PrimaryExaminer.lohn F. Campbell Assistant Examiner-Ronald .1. ShoreAttorney-Waters, Roditi, Schwartz and Nissen [57] ABSTRACT A method ofmanufacturing multilayer components with inner hollows by the explosivewelding of metal blanks, one of the blanks being provided withdepressions filled with fusible or soluble materials which are removedafter welding.

3 Claims, 5 Drawing Figures PAHiN'lLu mm mm METHOD OF MANUFACTURINGCOMPONENTS WITH CAVITTES BY EXPLOSTVE WELDING OF METAL BLANKS Thepresent invention relates to welding practices, and more particularly tomethods of producing components with inner cavities by the explosivewelding of metal blanks, said components being employed, for example, invarious branches of the machine-building industry.

Cooled walls of molds in continuous steel casting plants, walls of jetengine nozzles and so forth may be referred to as examples of componentsof the aforementioned type.

At present, the above indicated components are made by joining twoblanks with the aid of conventional methods involving the use of boltedjoints, brazing, resistance welding and so forth, which, as a rule, donot provide high-strength joints and do not insure sufficient airtightness thereof. In addition, the prior-art methods involve muchlabor.

Attempts have also been made to use prior-art methods of explosivewelding to obtain metal components with cavities. However, untilrecently such attempts proved to be unsuccessful.

The difficulty in producing parts with cavities lies in the fact thatonly certain areas of the blanks should be welded together, as well asin the fact that the impact of the plate to be welded on against thebase plate causes destruction of the plate to be welded on, which is dueto the latters partially entering depressions made in the surface of thebase plate as a result of which airtightness of the produced componentis not secured. Further, after the blanks are joined together, innercavities of intricate shape can not be made with any of the conventionalmethods.

An object of the present invention is to provide a simple and reliablemethod of producing components with inner cavities by the explosivewelding of metal blanks. Another object of the present invention is toeliminate labor-consuming operations in the production of componentswith inner cavities.

A further object is to make available components with a quality weld andwith cavities of various configurations.

In accordance with the above-mentioned and other objects, the inventionconsists in that in the method of producing components with innerhollows by means of the explosive welding of metal blanks according tothe invention, that are made in at least one welding surface of a baseblank depressions to be then filled with a lower-melting metal, forinstance tin, and then there is joined to the welding surface of thebase blank by explosive welding at least one blank to be welded on,after which the low-melting metal is fused out from the thusly formedhollows of the produced component.

In another method of producing components with inner hollows by theexplosive welding of metal blanks according to the invention, there aremade in at least one welding surface of the base blank depressions to bethen filled with a soluble material, for instance sodium chloride, andthen there is joined to the welding surface of the base blank byexplosive welding at least one blank to be welded on, after which thesoluble material is removed from the thusly formed hollows of themanufactured component.

It is preferred that a thinner blank should be first welded, by theexplosive method, to at least one welding surface of the base blank withthe filled depressions.

Other objects and advantages of the present invention will become morefully apparent from a consideration of the following description, takenin conjunction with the accompanying drawings, in which:

FIG. 1 shows diagrammatically, according to the invention, a base metalblank provided with depressions filled by a low-melting metal or asoluble material, and the blank to be welded-on with an explosive chargeplaced thereon (there being shown a longitudinal section across one ofthe depressions).

FIG. 2 is a top view of the arrangement of FIG. 1 without the charge,the blank to be welded-on being partially cut away;

FIG. 3 is a sectional view along section line III-III in FIG. 1;

FIG. 4 shows a smaller arrangement with a thinner metal blank pre-weldedby the explosive method (there being shown a longitudinal section acrossone of the depressions); and

FIG. 5 is a cross-sectional view along section line VV in FIG. 4.

In disclosing the following embodiments of the invention shown in theaccompanying drawings, specific terminology is used for the sake ofclarity. However, the concise terms employed therein should not beregarded as in any way limiting the invention, and it should be borne inmind that each such term comprehends all possible equivalent membersworking in a similar way and which can be employed to solve the sameproblems.

Production of components with hollows by the explosive welding of metalblanks according to the invention is carried into effect as follows.

Made by one of the conventional methods, say machining, on the weldingsurface of the base blank 1 (FIGS. 1-5) are depressions 2 of a requiredconfiguration conforming to the shape and dimensions of the desiredcavities. Depressions 2 are filled with a lowmelting metal 3, say tin,or a soluble material 3, say sodium chloride, after which at least oneblank 4 to be welded on is joined to the welding surface of base blank Iby explosive method. Welding is effected by initiating the detonation ofan explosive charge 5 placed on a blank 4 to be welded on, detonator t5effecting the initiation. The low-melting metal or soluble material isthen removed from the formed hollows of the manufactured component byfusing or dissolving the same. The thusly welded component is thensubjected to further work Impact of blank 4 to be welded on against baseblank 1, having depressions 2, produces a firm joint. The lowmeltingmetal or soluble material filling depressions 2, and the metal of blank4 to be welded on do not weld together at all or form a weak joint whichis readily destroyed by fusion or dissolving.

To exclude the possibility of breaking blank 4 to be welded on, and toimprove the weld quality, a thinner metal blank 7 (FIGS. 4 and 5) can befirst welded, by the explosive method, to the welding surface of baseblank 1 with filled depressions 2, said thinner blank firmly welding,during the impact, with the metal of base blank 1. The low-melting metalor soluble material filling depressions 2, and blank 7 do not weldtogether at all, or form a weak joint. At least one blank 4 to be weldedon is then explosion-welded to the surface of the metal blank 7.

The explosive charge can be set off not only by detonator 6, but by adetonating cord or a plane-wave generator (not shown in the drawings) aswell. The place of initiation is chosen according to the shape ofdepressions 2, so that the front of detonation can spread along theprincipal directions of the depressions.

According to the invention, several blanks 4 can be simultaneouslywelded to base blank 1. In case several blanks 4 are welded to baseblank 1 on one side thereof, the explosive charge 5 is placed only onthe furthermost blank 4 with respect to base blank 1. When one orseveral blanks 4 are required to be welded to base blank 1 on both sidesthereof, explosive charges 5 are located on the extreme blanks 4 to bewelded on. In the latter case, either separate depressions 2 are formedon each welding surface of base blank 1, or through recesses are made inthis blank.

Manufacturing of components with inner cavities by the explosive weldingof metal blanks according to this invention has the followingadvantages:

filling the depressions made in the base blank with a low-melting metalor a soluble material and subsequent welding of at least one blank tothe said base blank permits components with inner cavities of variousconfigurations to be obtained, using a wide combination of metals in theinitial blanks and insuring a quality joint therebetween; additionally,the consumption of labor and of scarce materials used in the productionof components with inner hollows is greatly decreased.

This method has been effectively used to manufacture a bimetalic cooledwall of the mold for a continuous steel casting machine.

Though the present invention is disclosed in connection with itspreferred embodiment, it is obvious that there may be many modificationsand variants thereof that do not depart from the idea and scope of theinvention which will be easily understood by those skilled in the art.These modifications and variants are considered to fall within theessence and scope of the invention as defined by the appended claims.

What we claim is:

1. A method of manufacturing components with inner hollowsby theexplosive welding of metal blanks, said method comprising forming in atleast one welding surface of a base blank depressions which are thenfilled with a removable material, welding to the base blank to coversaid material and enclose the same in said depressions a relatively thinsecond blank, welding over the relatively thin second blank by anexplosive welding technique at least one further blank, and thenremoving said material from the thusly formed hollows of the compositestructure.

2. A method as claimed in claim 1 wherein the material is fusible.

3. A method as claimed in claim 1 wherein the material is soluble.

2. A method as claimed in claim 1 wherein the material is fusible.
 3. Amethod as claimed in claim 1 wherein the material is soluble.